An efficient simulation tool for predicting chatter during cutting operations

The trends in chatter prediction are to compute stability lobes showing the maximal depth of cut versus spindle speed, following the work of Tlusty, Tobias and, more recently, Altintas. For mass production such as the production of automotive parts, this kind of approach is not suitable because the goal is to find cutting conditions stable and independent of perturbations inherent to machining (clamping, rough part dimensions...). Still, in this method, the greatest allowable depth of cut to avoid chatter at any spindle speed is considered. The model is based on Tlusty's theory and the local stiffness of the machined surface is computed through a static finite element analysis. The result is a chatter map of the machined surface showing the maximal depth of cut at each node.